Method for manufacturing a pre-cast deck, dock steps and dock system

ABSTRACT

A method of manufacturing a pre-cast deck, dock step(s) and dock is disclosed utilizing 2 main components, beam(s) and slab(s). Optional accessories are also disclosed that may be added such as hand rail(s), boat bumper(s) and water access ladder(s).

This Nonprovisional Continuation/Divisional application for patentincorporates by reference and claims the benefit and priority of pendingNonprovisional Application having Ser. No. 10/912,719 filed Aug. 5, 2004for “Pre-cast Deck, Dock Steps and Dock System,” commonly owned with theinstant application.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to pre-cast concrete products.The invention particularly relates to pre-cast decks, dock steps anddocks, as they are commonly referred to in the marine industry. Theinvention more particularly relates to pre-cast decks, dock steps anddocks utilized over existing sea walls and uniquely anchored usingcantilever methods and earth support behind the existing sea wall andnot using conventional vertical pilings driven into the sea floor per isthe custom and practice in the marine industry. Additionally, theexisting sea wall is not stressed laterally by the dock pulling on theexisting sea wall in the conventional manner due to the unique anchoringmethod on the shoreline. This invention reinforces and earth anchors theexisting (or optionally new) sea wall.

2. Description of the Prior Art

On the shoreline, sea walls and docks for mooring boats and waterfrontactivities have been in use for many years. The shoreline (or sea wall)define the inland side (inland end) of the shoreline (or sea wall) andthe water side (water end) of the shoreline (or sea wall) where thewater activities (swimming, boating, diving, etc.) occur. Conventionaldock systems use vertical pilings, typically made of wood or concrete,driven into the sea floor and used to support the dock above the waterline on beams spanning between the pilings. Additionally, docks used inconjunction with an existing sea wall typically use the sea wall for asupport member at the water's edge. This prior art method placesadditional loads and stress on the existing sea wall via a ledgeanchored to the top water side face of the sea wall and used for supportof the dock. This is especially important for safety reasons, if theexisting sea wall was not originally designed for the added loads andstress. These added loads and stress on the existing sea wall may causestructural or at the least cosmetic damage to the existing sea wall.

U.S. patent application Ser. No. 10/042,871 by Johnson discloses acantilevered structural support and mentions uses of docks and piers,but contains no steps and discloses no use of the seawall, as does thepresent invention.

None of the prior art addresses or solves this problem. This new anduseful pre-cast deck, dock steps and dock invention solves these marinedock industry problems in a safe and economical manner.

SUMMARY OF THE INVENTION

It is an object of the invention to help prevent disturbance of the seafloor for docks and dock step systems when constructed in conjunctionwith sea walls.

It is another object of the invention to allow a pre-cast, modularsystem to be installed over existing or new sea walls with anindependent anchoring system that reduces loads and stress on the seawall.

It is a further object of the present invention to allow the earthbehind the sea wall to be an anchor point for the deck, dock step(s) anddock system for a cantilever beam design supporting at least onepre-cast slab used as a deck, at least one pre-cast slab used as a stepand at least one pre-cast slab used as a dock extending out over thesurface of the water with no piling supports in the sea floor.

Another object is to provide fast, efficient dock erection with theleast on-site field work needed due to the pre-cast design andconstruction.

The objects of this invention are achieved and the present inventionprovides a new and useful system, article of manufacture and process formaking said article of manufacture comprising a pre-cast deck, dockstep(s) and dock, (the preferred embodiment of which is disclosed inFIG. 21, FIG. 22, FIG. 23 and FIG. 24) which can be integrated anywhereinto the shoreline but preferably integrated into or attached to theexisting sea wall and cantilevered at or over the water's surface forboating, swimming or other uses.

This invention is of simple construction that is easy to make and useand needs very little maintenance.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a side view of the cantilever Z beam with reinforcementbars therein.

FIG. 2 depicts a top view of the cantilever Z beam with reinforcementbars therein.

FIG. 3 depicts a top longitudinal sectional view of the slab withreinforcing bars.

FIG. 4 depicts a side longitudinal sectional view of the slab withreinforcing bars.

FIG. 5 depicts a cross-sectional view of the slab with reinforcing bars.

FIG. 6 depicts the optional pre-cast sea wall component.

FIG. 7 shows the pre-cast concrete mold for the cantilever Z beam withreinforcement bars therein, ready to pour concrete for manufacture.

FIG. 8 shows the pre-cast concrete gang mold for mass production (3 at atime) of the slabs with reinforcement bars therein, on tilt table andready to pour concrete for manufacture.

FIG. 9 depicts the optional pre-cast sea wall component with thecantilever Z beam placed perpendicular to and on top of the sea wall,with the inland side of the beam extending over the prepared earth andthe water end of the beam extending over the water's surface.

FIG. 10 depicts a close-up detail of the heel of the beam and wedgingagainst the side of the sea wall.

FIG. 11 depicts the beam, sea wall and industry standard rebars in theholes of the inland side of the beam.

FIG. 12 depicts a close-up detail of the industry standard rebars in theholes of the inland side of the beam.

FIG. 13 depicts a perspective view of the partial system with the earthanchor (concrete deadman) poured in place, securing the inland side ofthe beam.

FIG. 14 depicts a side sectional view of the partial system with theearth anchor (concrete deadman) poured in place, securing the inlandside of the beam.

FIG. 15 depicts a perspective view of the partial system with the earthanchor (concrete deadman) poured in place, securing the inland side oftwo (2) beams.

FIG. 16 depicts a top view of the partial system with the earth anchor(concrete deadman) poured in place, securing the inland side of two (2)beams.

FIG. 17 depicts a perspective view of the partial system with the deckslabs on the top surface of the inland end of the beam.

FIG. 18 depicts a side sectional view of the partial system with thedeck slabs on the top surface of the inland end of the beam.

FIG. 19 depicts a perspective view of the partial system with the deckslabs on the top surface of the inland end of the beam and step slabsintegrated into the top surface of the beam.

FIG. 20 depicts a side sectional view of the partial system with thedeck slabs on the top surface of the inland end of the beam and stepslabs integrated into the top surface of the beam.

FIG. 21 depicts a perspective view of the completed system with the deckslabs on the top surface of the inland end of the beam, step slabsintegrated into the top surface of the beam and dock slabs on the topsurface of the water side of the beam.

FIG. 22 depicts a side sectional view of the completed system with thedeck slabs on the top surface of the inland end of the beam, step slabsintegrated into the top surface of the beam and dock slabs on the topsurface of the water side of the beam.

FIG. 23 depicts a perspective view of the completed deck, dock steps anddock system with the optional hand rails, boat bumpers and water accessladders integrated into the system.

FIG. 24 depicts an alternative embodiment of the dock and dock stepssystem with an angled front edge at the water line (curved front edgemay also be used).

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The apparatus of the invention is conveniently fabricated byconventional and standard methods using conventional and standardmaterials common in the concrete and pre-cast fabrication industries.The preferred material is pre-cast concrete, but other materials may beused.

For example, the dock and dock step(s) system (“the system”) may befabricated from aluminum, stainless steel or like metals or any othersuitable material, even wood. The system may also be fabricated fromnon-metallic materials for lighter weight and corrosion resistance.Theses non-metallic materials include, among others, conventionalpolymers such as, for example, polystyrene, polycarbonate, polyurethane,polyethylene, phenol formaldehyde resins, polybutylene, Teflon and thelike. These above-mentioned materials are examples and do not limit thetypes of materials that can be used to make and use the system; any andall suitable materials may be used. The components of the system may beintegrated together by standards means such as pouring, casting,welding, bolting, gluing, riveting, or any other suitable means.

The system and method of making and using the invention will now befurther described and exemplified by reference to the various specificembodiments set forth in the drawings. The Figures illustrate views ofthe preferred embodiment of the invention.

Again referring to the Figures, the assembly and fabrication (making) ofthe preferred embodiment of the invention will be described in detail.The system is assembled and fabricated from standard materials andmethods now used in the appropriate industries. Typically, the system isa pre-cast concrete beam, slab(s) and step(s) solidly connected to theeach other to form a body. The body is typically at least one rigidhorizontal modified Z-shaped beam member of sufficient strength, length,width and depth to accomplish support of the weight of at least anaverage or above average person. The dock is typically at least onepre-cast concrete slab horizontal member directly (or indirectly)bearing on the beam of sufficient strength, length, width and depth toaccomplish support of the weight of at least an average or above averageperson. The step(s) are typically at least one rigid horizontal memberof sufficient strength, length, width and depth to accomplish support ofthe weight of at least an average or above average person. Optionally,the steps may be made of slip-resistant design integrated into the topsurface of the step(s). Or, a slip-resistant finish may be applied tothe top surface of the step(s). Typically, the attachment means employedfor attaching the system to the earth and sea wall is sufficient toaccomplish support of at least the weight of an average or above averageperson. The preferred earth attachment means are reinforcing rod anchorshorizontally and optionally vertically to anchor each section and pouredinto place with concrete at the site for support. The system istypically fabricated from pre-cast concrete, formed using conventionalpre-cast techniques such as forming, pouring, cutting, smoothing,curing, removing the forming and polishing or finishing. The system isshown with its design, functional aspects and relationship of componentsin scalable form in all of the drawings combined. The openings in thesystem allow for wave action to dissipate without undue stress createdon the system or integrated sea wall. Or, in another embodiment, anoptional pre-cast sea wall is first placed at the shoreline, backfilledand then used for support for the deck, dock-step and dock components.All of the inventor's shop drawings, notes, specifications, workingdrawings, plans, manuals and all other related printed and writtendocuments are hereby incorporated herein by reference

To make the system in the preferred embodiment and best mode, it isformed by the manufacturer in the appropriate shaped forms. The entiresystem uses two (2) basic components. A cantilevered Z beam is the firstcomponent. The cantilever Z beam(s) are a modified Z-shape as depictedin FIG. 1. FIG. 2 shows a top view of the beam. Typically, thecantilever Z beam is about 12 inches wide, extends about 10 feet backfrom the sea wall onto the land, steps down twice about 8 inches eachstep and projects outward over the water's surface about 5 feet.Typically the steel reinforcement bars are industry standard rebars.Alternately, steel “I” beam, stainless steel rods, epoxy coated rebar,galvanized rebar, steel or fiberglass mesh or any other suitablereinforcement means can be used.

The second component is a slab. FIG. 3, FIG. 4 and FIG. 5 shows the slabdetails. The slab is modular in nature and typically 8 feet long, 1 footwide and 3 inches deep as shown in the above-referenced drawings.Typically the steel reinforcement bars are industry standard rebars.Alternately, steel “I” beam, stainless steel rods, epoxy coated rebar,galvanized rebar, steel or fiberglass mesh or any other suitablereinforcement means can be used. The slab is used in modular units onthe top surface of the cantilever Z beam to build the patio surface overthe shoreline, the steps and the dock projecting over the water'ssurface.

FIG. 6 shows the optional pre-cast sea wall is typically 6 feet tall, 1foot deep (or sloped with a variable depth), 20 feet wide, and on anintegrated pre-cast foundation slab about 4 feet back into theearth-side of the sea wall and 1 foot into the water-side of the seawall. Typically the steel reinforcement bars are industry standardrebars. Alternately, steel “I” beam, stainless steel rods, epoxy coatedrebar, galvanized, rebar, steel or fiberglass mesh or any other suitablereinforcement means can be used.

Ideally, the two basic components (and the third optional component) arefabricated in an PreCast Concrete Association of America (PCAA)certified pre-cast plant using approved standards for reinforcing,concrete mix designs, casting procedures, quality control, etc. andcomplying with all local codes and American Concrete Institute (ACI)-318requirements. All related manuals, specifications and other printeddocuments generated by PCAA and ACI are hereby incorporated byreference.

To make the invention, appropriate steel angle perimeter molds, panmolds and gang form molds (for mass production) in the properdimensions, all typical in the pre-cast industry, are used on either asmooth casting surface or steel casting tilt-table. FIG. 7 shows atypical cantilevered Z beam mold 17 with rebars 18 inserted on chairs,ready to be poured with concrete. FIG. 8 shows a typical gang form 19with 3 typical slabs with rebars 20 on chairs in the molds, on a steeltilt-table, ready to be poured with concrete.

Typically, the concrete is 4,000 PSI and chemicals may be added forhardening, curing and chloride (salt) resistance. In best mode, theconcrete cures in 24 hours, enabling the forms of the slab(s) andcantilevered Z beam(s) to be stripped and the components stored about 20days for final curing. After the components are fully cured, they areloaded onto a suitable truck (typically a flat-bed). A typical unit ofthe pre-cast dock step system contains (2) two cantilevered Z beams and(14) fourteen slabs spanning between the beams. These components willbuild a system with a 9 feet long by 8 feet wide deck on the land-sideof the shoreline, two 12 inches long by 8 feet wide steps (with 8 inchrisers) leading down to a 3 feet long by 8 feet wide dock protrudingover the water's surface. For wider decks, steps and docks, more of theabove-referenced units are constructed on either side of the first unitat the appropriate spacing. The above-referenced dimensions areillustrative only and used merely as examples, as the system may be madein any and all dimensions (sizes) desired by the manufacturer and user.

The above-referenced components are then trucked to the site at theshoreline where the system is to be erected. The site is prepared byexcavating or adding clean dirt fill, as needed, to provide a levelearth surface inland, typically 9 feet minimum from the sea wall.

Referring now to FIG. 9, the first cantilevered Z beam 1 is unloadedfrom the truck with a fork-lift, suitable crane or manpower and set ontothe top of the existing sea wall (or optional pre-cast sea wall 0). FIG.10 shows the heel 2 of the cantilevered Z beam 1 against the sea wallwith wedging 3 (typically polychloride vinyl or similar mastic orhydraulic cement or other suitable wedging material) in the heel 2. Thewedging 3 provides a cushion for both load bearing and to displacebending stress (moment) to the water-side surface of the sea wall andearth dead weight behind the sea wall.

Next, as shown in FIG. 11 and FIG. 12, at least one horizontal rebar(s)4 and optional vertical rebar(s) 5, if desired, in the pre-formed holes6 in the inland end 7 to be used as an earth anchor. The earth anchor isshown in FIG. 13 and FIG. 14 by excavating or forming a deadman 8 about3 feet in diameter and 1 foot deep around the inland end 7 of thecantilevered Z beam 1 and poured solidly with concrete (typically 2,500PSI) and allowed to cure, which encases completely the horizontalrebar(s) 4 and optional vertical rebar(s) 5 in the pre-formed holes 6.The deadman 8 prevents uplift at the inland end 7 of the cantilevered Zbeam 1 and helps keep the sea wall rigid and helps prevent “creep” ofthe sea wall due to the earth's static pressure.

The second cantilevered Z beam 1 is unloaded from the truck andinstalled in the exact same above-referenced manner as shown in FIG. 15and FIG. 16 about 8 feet parallel to the first cantilevered Z beam 1.

Then, the slab(s) 9 are unloaded from the truck and placed perpendicularto and spanning between on the top surface of the inland end 7 of thefirst and second cantilevered Z beams 1 one at a time until (9) nineslabs are laid on the inland-side top surfaces of the first and secondcantilevered Z beams 1, making the deck, a shown in FIG. 17 and FIG. 18.All slabs are integrated onto the top surface of the cantilevered Zbeam(s) 1 with their dead weight and secured with an appropriateadhesive mastic.

Then, (1) one slab 9 is placed perpendicular to and spanning between onthe top surface of the step one 10 and (1) one slab 9 is placedperpendicular to and spanning between on the top surface of step two 11,as shown in FIG. 19 and FIG. 20, making (2) steps with 8 inch risers 12.

Next, the last (3) three slab(s) 9 are placed perpendicular to andspanning between on the top surface of the water end 13 of the first andsecond cantilevered Z beams 1 one at a time until the (3) three slabsare laid on the water end 13 top surfaces of the first and secondcantilevered Z beams 1, making the dock, a shown in FIG. 21 and FIG. 22.The invention is completed and ready to use. Throughout thisapplication, (s) indicates either singular or plural.

If desired, more units may be added in the exact same mannerabove-described (in the appropriate dimensions i.e. end-to-end,end-to-center or center-to-center) and other optional components may beadded (attached with typical concrete anchoring devices or fasteners)such as hand rail(s) 14, boat bumper-rails 15 (either vertical orhorizontal) and water access ladder(s) 16 as shown in FIG. 23.Optionally, a slip resistance surface coating may be applied to one,some or all of the slabs. Or, roughened top surfaces of the slabs may beintegrated in the forms when manufactured in the pre-cast plant.

As will be apparent to persons skilled in the art, such as a structuralengineer, pre-cast concrete manufacturer or pre-cast concrete builder,various modifications and adaptations of the structure and method of useabove-described will become readily apparent without departure from thespirit and scope of the invention, the scope of which is defined in theclaims. Although the foregoing invention has been described in detail byway of illustration and example, it will be understood that the presentinvention is not limited to the particular description and specificembodiments described but may comprise any combination of the aboveelements and variations thereof, many of which will be obvious to thoseskilled in the art. Additionally, the acts and actions of fabricating,assembling, using, and maintaining the preferred embodiment of thisinvention is well known by those skilled in the art. Instead, theinvention is limited and defined solely by the following claims.

The invention may be embodied in other specific forms without departingfrom the spirit or essential characteristics thereof. The presentembodiment is therefore to be considered in all respects as illustrativeand not restrictive, the scope of the invention being indicated by theappended claims rather than by the foregoing description, and allchanges which come within the meaning and range of equivalency of theclaims are therefore intended to be embraced therein.

24. A method for manufacturing pre-cast concrete deck, dock step(s) anddock components said method comprising the steps of: (a) assembling theappropriate pre-cast concrete molds in a suitable work area; (b) placingthe assembled molds on an appropriate concrete casting surface; (c)adding the appropriate reinforcement to the assembled molds or concrete;(d) adding the appropriate chemicals to the concrete, if desired; (e)pouring the concrete into the pre-cast concrete mold(s); (f) waiting forthe concrete to cure for the appropriate amount of time; (g) strippingthe forms from the hardened concrete; (h) storing the concrete deck(s),dock step(s) and dock(s) for the appropriate amount of time for finalcuring.
 25. The method of claim 24 wherein the chemicals added to theconcrete are selected from the group consisting hardening chemicals,curing chemicals and salt resistant chemicals.